Key Takeaways
- Three Mayfield City Schools seniors won second place at the Ohio SkillsUSA competition with a novel packaging automation device.
- The project was developed in partnership with Ranpak, a local packaging firm, to streamline manual paper‑wrap processes.
- Students designed, prototyped, and iterated a “Fly Trap” system that replaces error‑prone hand‑wrapping with a button‑activated mechanism.
- They faced and overcame last‑minute design hurdles, tracking every change meticulously over a 15‑week period.
- The program’s engineering technology curriculum and mentor guidance were highlighted as pivotal to their growth and future career plans.
- The team remains hopeful about patent approval and potential integration of their invention into Ranpak’s production line.
Student Recognition
The three seniors—Caleb Rivchun, Edward Kovach‑Uzl, and Harrison Horvath—are recent graduates of the Mayfield City Schools ExcelTECC CADD Engineering Technology program. Their achievement was celebrated in a local news feature that highlighted not only their competition ranking but also the skill set they honed throughout the program. Their success exemplifies how high‑school engineering pathways can launch students directly into professional problem‑solving environments.
Engineering Competition Project
The team’s competition entry addressed a specific operational challenge faced by Ranpak: automatically wrapping irregularly shaped objects in protective brown paper. Rather than developing the solution independently, the students leveraged school resources and industry expertise to tackle the real‑world problem, aligning with SkillsUSA’s emphasis on applied technical skills.
Partnership with Ranpak
Ranpak, a Concord Township‑based packaging company, supplied the technical context and mentorship required for the project. Imtiaz Shaha, the company’s vice president of engineering, worked closely with the students to isolate the core issue and guide the design process. This collaboration gave the students access to professional workshops, 3D‑printing facilities, and critical industry insight.
Problem Identification
Through initial brainstorming sessions, the team pinpointed the inconsistencies and inefficiencies of manual paper‑wrapping performed by operators. They recognized that human variability often led to gaps or mis‑wraps, prompting the need for a repeatable, low‑margin‑error mechanism. This insight shaped their focus on creating a reliable, repeatable solution.
Design and Prototyping Process
The students employed a rapid‑iteration workflow: cardboard mock‑ups, detailed drawings, 3D‑printed components, and iterative testing. Each new design was reviewed by Ranpak engineers before printing, ensuring that feasibility and safety were addressed early. Their systematic documentation allowed them to track every modification and rationale throughout the development cycle.
Iterative Design Challenges
Midway through the project, a critical flaw emerged in the circular base design that prevented the paper from fully enveloping the product. The team responded by scrapping the previous iteration and redesigning the “fingers” mechanism, a change made only days before the competition deadline. This pivot underscored their resilience and ability to adapt under pressure.
Solution Development
After numerous iterations, the team settled on a final prototype that functioned by pulling a string or pressing a button to automate the wrapping process. They dubbed the concept the “Fly Trap” and secured a second‑place finish among 25 competing teams. The solution balanced mechanical reliability with user‑friendly operation, emphasizing consistency over human variability.
Competition Outcome
Finishing second out of 25 teams was a notable accomplishment that reflected both the technical quality of their design and the effectiveness of their collaborative approach. Their victory earned them recognition from SkillsUSA and positioned them for future professional opportunities, including a potential patent filing that could take up to a year to finalize.
Future Prospects and Patent
While the competition has concluded, the students remain focused on securing a patent for their invention. Their ultimate goal is to see Ranpak adopt the device on its production floor, thereby enhancing operational efficiency while preserving human labor. They envision the technology as a complement rather than a replacement for workers, aiming to reduce errors and streamline repetitive tasks.
Program Impact and Mentorship
Both students and mentors praised the ExcelTECC CADD Engineering Technology program for providing the foundational knowledge, hands‑on experience, and professional mentorship essential to their success. Teacher Craig Schmidt’s instruction in computer‑aided design was singled out as a catalyst that opened doors to college admissions and career pathways, notably for Caleb Rivchun’s upcoming enrollment at Ohio State University.
Reflections and Lessons Learned
The team emphasized that the project’s value transcended monetary gain; it underscored the importance of teamwork, iterative problem solving, and mentorship. Their experience highlighted how high‑school engineering programs can serve as launchpads for real‑world innovation, connecting students with industry partners and giving them a voice in practical solutions.
Conclusion
The story of these three seniors illustrates how collaborative education, industry partnership, and resilient design thinking can produce award‑winning engineering solutions. Their journey from classroom concepts to competition podiums not only validates the efficacy of the ExcelTECC program but also foreshadows a promising future for these young engineers as they transition into higher education and professional careers.